🏷️ Basic Information

Make:

Mazda

Model:

Protege

Year:

2002

Product Name:

Mazda Protege 2002 Workshop Manual.rar

Product Description:

Mazda Protégé 2002 Workshop Service Manual

Generation Designation:

BJ (Second Generation)

Generation Years:

1998-2003

👋 Introduction

Market Segment:

Compact/Subcompact car, appealing to budget-conscious buyers seeking reliability and practicality.

Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Hyundai Elantra

Key Selling Points:

Fuel efficiency, nimble handling, good value for money, availability of sedan and hatchback body styles.

Usefulness For Diy:

Essential for Do-It-Yourself mechanics, offering comprehensive guidance for repairs and maintenance, saving on labor costs.

Completeness Claim:

Claimed to be the 'most complete' manual compiled, suggesting extensive coverage of all major vehicle systems.

📋 Manual Details

Main Sections:

General Information, Engine, Suspension, Driveline/Axle, Brakes, Transmission/Transaxle, Steering, HVAC, Restraints, Body & Accessories

Page Count:

952

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

Digital (RAR archive, likely containing PDF or similar document formats)

📖 Manual Coverage

Engine Systems:

On-Board Diagnostics (ZM, FS engines), Cruise Control System, Symptom Troubleshooting (ZM, FS engines), Mechanical (ZM, FS engines), Lubrication, Cooling System, Intake-Air System (ZM, FS engines), Fuel System, Exhaust System, Emission System, Charging System, Ignition System, Starting System, Cruise Control System, Control Systems (ZM, FS engines)

Drivetrain Systems:

Suspension (General Procedures, Wheel Alignment, Front/Rear Suspension, Technical Data), Driveline/Axle (General Procedures, Front/Rear Axle, Drive Shaft, Technical Data), Transmission/Transaxle (On-Board Diagnostics, Symptom Troubleshooting, Clutch, Manual Transaxle [F25M-R, G15M-R], Manual Transaxle Shift Mechanism, Automatic Transaxle, Automatic Transaxle Shift Mechanism, Technical Data)

Chassis Systems:

Brakes (On-Board Diagnostics, Symptom Troubleshooting, General Procedures, Conventional Brake System, Parking Brake System, ABS, Technical Data), Steering (General Procedures, Engine Speed Sensing, Power Steering, Technical Data)

Body And Comfort Systems:

HVAC (Symptom Troubleshooting, Refrigerant System, Basic System, Control System, Technical Data), Restraints (On-Board Diagnostics, Symptom Troubleshooting, Air Bag System, Seat Belt), Body & Accessories (On-Board Diagnostics [Power Door Lock, Audio], Body Panels, Doors and Liftgate, Glass/Windows/Mirrors, Seats, Security and Locks, Sunroof, Exterior Trim, Interior Trim, Lighting Systems, Wiper/Washer System, Entertainment, Power Systems, Instrumentation/Driver Info)

Maintenance Procedures:

Oil change, filter replacement, fluid level checks, coolant flush, brake fluid change, belt inspection/replacement, spark plug replacement, air filter replacement, fuel filter replacement, tire rotation

Diagnostic Procedures:

On-board diagnostics (OBD-II), symptom-based troubleshooting for engine, transmission, brakes, HVAC, restraints, and electrical systems, diagnostic trouble codes (DTCs)

Repair Procedures:

Engine mechanical (timing belt, head gasket, internal components), transmission overhaul (manual and automatic), brake caliper/rotor replacement, suspension component replacement (struts, ball joints, bushings), steering rack replacement, exhaust system repair, HVAC component replacement (compressor, evaporator), electrical component testing and replacement, body panel repair and replacement, window/door regulator repair

Special Procedures:

Wheel alignment, air bag system servicing, ABS system bleeding, refrigerant system evacuation and recharge, cruise control system diagnosis and repair

Technical Depth:

Comprehensive, covering basic maintenance to advanced diagnostics and complete rebuilds. Includes detailed procedures, torque specifications, wiring diagrams (likely, though not explicitly stated), and troubleshooting flowcharts.

📊 Manual Specifications

File Format:

RAR archive. Expected content format: PDF, DOC, or proprietary manual viewer format.

Print Quality:

Described as 'high quality diagrams', implying good detail for printout or digital viewing.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code:

ZM

Engine Type:

Inline 4-cylinder, DOHC

Displacement:

1.5 Liters (1498 cc)

Bore X Stroke:

78.0 mm x 78.4 mm

Compression Ratio:

9.5:1

Horsepower:

100 hp @ 6000 rpm

Torque:

95 lb-ft @ 4000 rpm

Engine Code:

FS

Engine Type:

Inline 4-cylinder, DOHC, 16-valve

Displacement:

2.0 Liters (1991 cc)

Bore X Stroke:

83.1 mm x 92.0 mm

Compression Ratio:

9.1:1 (standard), 9.7:1 (SVT)

Horsepower:

118 hp @ 5500 rpm (standard), 170 hp @ 7000 rpm (SVT)

Torque:

122 lb-ft @ 4000 rpm (standard), 144 lb-ft @ 5000 rpm (SVT)

Fuel Delivery:

Electronic Fuel Injection (EFI)

🔧 Transmission

Transmission Type Standard:

5-Speed Manual

Transmission Type Optional:

4-Speed Automatic

Gear Ratios:

Refer to manual for specific ratios (e.g., 1st: 3.307, 2nd: 1.947, 3rd: 1.310, 4th: 1.000, 5th: 0.829, Reverse: 3.307, Final Drive: 4.300)

Gear Ratios:

Refer to manual for specific ratios (e.g., 1st: 3.416, 2nd: 1.842, 3rd: 1.233, 4th: 0.971, 5th: 0.844, Reverse: 3.166, Final Drive: 4.105)

Automatic Transmission Type:

4-speed electronically controlled automatic

Clutch Type:

Hydraulic actuated, single dry plate

📐 Dimensions

Length:

171.7 inches (4361 mm)

Width:

67.5 inches (1715 mm)

Height:

55.1 inches (1400 mm)

Wheelbase:

102.8 inches (2610 mm)

Length:

165.2 inches (4196 mm)

Width:

67.5 inches (1715 mm)

Height:

55.1 inches (1400 mm)

Wheelbase:

102.8 inches (2610 mm)

Cargo Volume Sedan:

12.4 cubic feet

Cargo Volume Hatchback:

22.1 cubic feet (seats up)

Curb Weight:

Approx. 2500 - 2700 lbs (depending on trim and engine)

Gross Vehicle Weight Rating:

Refer to vehicle placard

🛡️ Safety Features

NHTSA Front Impact Driver:

4 Stars (2002 model year)

NHTSA Front Impact Passenger:

4 Stars (2002 model year)

IIHS Front Offset Crash Test:

Good (2002 model year)

ABS:

Available on some trims

Traction Control:

Not commonly available

Airbags:

Frontal airbags for driver and passenger

Seatbelts:

Three-point seatbelts with pretensioners for front occupants

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system

💡 Technology Features

Audio System:

Factory AM/FM/CD player, optional premium audio system, basic speaker setup.

Instrumentation:

Analog gauges for speedometer, tachometer, fuel level, and engine temperature. Warning lights for various systems.

Cruise Control:

Available as an option on many trims.

Aux Input:

Not standard on factory audio systems.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually.

Engine Coolant Flush:

Every 30,000 miles (48,000 km) or 2 years.

Spark Plug Replacement:

100,000 miles (160,000 km) for iridium plugs, 30,000 miles (48,000 km) for conventional.

Timing Belt Replacement:

Every 60,000 miles (96,000 km) or 5 years (interference engine, critical replacement).

Engine Oil Type:

API SJ or higher, SAE 5W-30 (for ZM and FS engines)

Engine Oil Capacity:

Approx. 3.7 quarts (3.5 liters) with filter change (ZM), 4.3 quarts (4.1 liters) with filter change (FS).

Automatic Transmission Fluid:

Dexron III / MERCON

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (for F25M-R and G15M-R)

Power Steering Fluid:

Dexron III / MERCON or Mazda Genuine ATF (Type III)

Coolant Type:

Ethylene Glycol based, Type A (Mazda Genuine Super Long Life Coolant or equivalent)

Common Problems:

Ignition coil failure, mass airflow sensor issues, power steering pump leaks, CV joint wear, exhaust manifold cracks (FS engine), sticky shifters (manual transmission), door lock actuator failure, rear main seal leaks.

📚 Vehicle History

Mazda Philosophy:

Jinba-Ittai (Horse and Rider as One), emphasizing driver connection and engaging dynamics.

Generation Overview:

The BJ generation Protege was a significant redesign, offering improved styling, a more refined interior, and updated mechanicals compared to its predecessor. Available in sedan, hatchback (Protege5 in some markets), and performance-oriented Mazdaspeed Protege variants.

Manufacturing Location:

Japan, Mexico (for North American markets)

Production Span:

1998-2003

🏆 Awards & Recognition

Car And Driver 10Best:

Protege (various trims) frequently appeared on Car and Driver's 10Best lists in the late 1990s and early 2000s, highlighting its value and driving dynamics.